Multileveled printed circuit board unit including substrate interposed between stacked bumps

ABSTRACT

Conductive or solder bumps are stacked between a mounted component such as a BGA device and a printed wiring substrate in a multileveled printed circuit board unit. An interposer or relay substrate is interposed between the adjacent stacked conductive bumps. The interposer substrate is made of a porous material. When any difference in the expansion is caused between the printed wiring substrate and the mounted component, one side of the interposer substrate receives a relatively smaller displacement force while the other side of the interposer substrate receives a relatively larger displacement force. A shearing stress is induced in the interposer substrate. Deformation of the porous material serves to absorb the shearing stress in the interposer substrate. The conductive bumps bonded on one side of the interposer substrate as well as the conductive bumps bonded on the other side of the interposer substrate may be relieved from a shearing stress. Accordingly, the durability of the conductive bumps can be improved. The conductive bumps are allowed to keep a stronger bonding in a longer duration.

This application is a division of prior application Ser. No. 09/749,505filed Dec. 28, 2000 now U.S. Pat. No. 6,697,261, which is a continuationof international application PCT/JP99/01263, filed Mar. 16, 1999.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a printed circuit board unit includingstacked solder or conductive bumps between a printed wiring substrateand a mounted component, and particularly, to an interposer or relaysubstrate interposed between the stacked conductive bumps.

2. Description of the Prior Art

A printed circuit board unit is well known to include a mountedcomponent such as a ball grid array (BGA) device, for example. When theelectric circuit generates heat in the printed circuit board unit, aheat or thermal stress is in general induced in the printed wiringsubstrate, made of a glass epoxy or polyimide resin, and the ceramicsubstrate of the BGA device. Since the printed wiring substrate made ofresin and the ceramic substrate have different thermal expansioncoefficients, the substrates usually suffer from a relative movement orshift along the surface of the printed wiring substrate due to thethermal expansion.

Such a relative movement between the printed wiring substrate made ofresin and the ceramic substrate induces a shearing stress in solderbumps disposed between the printed wiring substrate and the ceramicsubstrate. The shearing stress may repeatedly be generated in the solderbumps in response to switching between on and off statuses of theelectric circuit in the printed circuit board unit. The solder bumps maysometimes suffer from cracks when the shearing strain finally overcomesthe strength of the solder bumps. The thus repeated and intermittentgeneration of the shearing stress is supposed to deteriorate thedurability of the solder bumps.

It is conventionally known that a higher or taller solder bump leads toreduction in the shearing stress induced in the solder bump. A highersolder bump contributes to a broader distribution of the shearingstress, so that a smaller shearing stress can be defined within ahorizontal cross-section of the solder bump. However, an increase in theheight of a spherical solder bump or solder ball inevitably induces anincrease in the width of the solder ball. A higher or taller solder ballin this manner is supposed to suffer from a smaller distribution densityof the solder balls.

In view of the above-described disadvantage, it is proposed that solderbumps are vertically stacked on the printed wiring substrate below themounted component. The stacked solder bumps are supposed to realize anincrease in the height without increasing the width. In this proposal,the solder bumps and relay substrates are alternately stacked on oneanother on the printed wiring substrate. The relay substrate serves toconnect the adjacent stacked solder bumps.

As disclosed in Japanese Patent Application Laid-open No. 09-214088, forexample, it is proposed that the thermal expansion coefficient of therelay substrate is set at an intermediate level between the thermalexpansion coefficients of the printed wiring substrate and the mountedcomponent. In this case, a shearing stress is equally distributed overthe stacked solder bumps. Japanese Patent Application Laid-open No.62-18049 still proposes to interpose a relay substrate in the form of afilm having a smaller Young's modulus between the stacked solder bumps.The relay substrate is supposed to absorb a larger shearing stress.

SUMMARY OF THE INVENTION

It is accordingly an object of the present invention to provide aninterposer or a relay substrate for a multileveled printed circuit boardunit capable of more efficiently absorbing a repetitive shearing stressinduced in conductive bumps stacked between a printed wiring substrateand a mounted component, and a printed circuit board unit employing thesame interposer.

It is another object of the present invention to provide an interposeror relay substrate capable of introducing additional functions in amultileveled printed circuit board unit.

According to a first aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising an interposer substrate made of a porousmaterial interposed between stacked conductive bumps.

In the multileveled printed circuit board unit employing the interposer,when any difference in the expansion is caused between the printedwiring substrate and the mounted component, one side of the interposersubstrate receives a relatively smaller displacement force while theother side of the interposer substrate receives a relatively largerdisplacement force. A shearing stress is induced in the interposersubstrate. Deformation of the porous material serves to absorb theshearing stress in the interposer substrate. The conductive bumps bondedon one side of the interposer substrate as well as the conductive bumpsbonded on the other side of the interposer substrate maybe relieved froma shearing stress. Accordingly, the durability of the conductive bumpscan be improved. The conductive bumps are allowed to keep a strongerbonding in a longer duration.

The porous material is preferably designed to define pores penetratingthrough the interposer substrate. The pore may be utilized to provide avia establishing an electric connection between the conductive bumps onthe opposite sides. It is not necessary to bore the interposer substratesolely for the via. Production process of the interposer substrate canbe facilitated.

The pore is designed as a slit located between adjacent ones of theconductive bumps arranged on an identical level. Even when one side ofthe interposer substrate receives a relatively smaller displacementforce while the other side of the interposer substrate receives arelatively larger displacement force in the aforementioned manner, ashearing stress can be absorbed by deformation of the slit. In thiscase, the size of the slit at a central area of the interposer substrateis preferably set smaller than that of the slit located at a arearemoter from the central area, since the planar displacement or shiftgets larger at a location remoter from the center of the interposersubstrate upon a thermal expansion of the printed wiring substrate andthe mounted component.

According to a second aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising multilayered films made of differentmaterials interposed between stacked conductive bumps.

It is possible to provide different characteristics at the oppositesides of the interposer substrate, respectively. For example, when thefilm contacting the mounted component may be made of a material having athermal expansion coefficient identical to that of the mountedcomponent, no shearing stress is induced in the conductive bumps betweenthe mounted component and the film. On the other hand, when the filmcontacting the printed wiring substrate may be made of a material havinga thermal expansion coefficient identical that of the printed wiringsubstrate, no shearing stress is likewise induced in the conductivebumps between the film and the printed wiring substrate. The material ofthe film contacting the mounted component may be selected from inorganicmaterials forming the substrate of the mounted component. The materialof the film contacting the printed wiring substrate is selected fromorganic materials forming the printed wiring substrate. A relativesliding movement between the films may be accomplished by an adhesivelayer interposed between the films. The adhesive layer may be made of anadhesive for coupling the films with each other.

According to a third aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit, comprising:a first conductive bump on a first level; and a second conductive bumpon a second level stacked on the first conductive bump between a printedwiring substrate and a mounted component, said second conductive bumphaving a size different from that of the first conductive bump.

In general, the larger the size or diameter of a conductive bump gets,the larger the strength of the conductive bump can be obtained. Thefirst and second conductive bumps are allowed to provide differentstrengths optimally required in the separate levels of the stackedconductive bumps, so that it is possible to minimize the size ordiameter of the first and second conductive bumps. The overall height ofthe stacked solder bumps can thus be reduced, keeping a requiredstrength. Alternatively, the first and second conductive bumps may bemade of different materials, so that diffusion bonding of variousstrengths can be obtained between the conductive bumps and theinterposer substrates as well as the other substrates, respectively.

According to a fourth aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps; and a conductive wiring pattern formedon the interposer substrate so as to electrically connect at least theconductive bumps arranged on an identical level.

In the multileveled printed circuit board unit employing the interposer,the conductive wiring pattern on the interposer substrate serves toestablish an alternative electric path for a disconnected wiring patternon the printed wiring substrate and/or the mounted component. Also, theconductive wiring pattern may establish a modified electric path inplace of a wiring pattern initially formed on the printed wiringsubstrate and/or the mounted component. In this case, two or morecomponents may be mounted on the interposer substrate. In such a printedcircuit board unit, the conductive wiring pattern on the interposersubstrate may serve to establish an alternative electric path for adisconnected wiring pattern on the printed wiring substrate so as toelectrically connect the mounted components to each other. Otherwise,the conductive wiring pattern may establish a modified electric path fora wiring pattern initially formed on the printed wiring substrate so asto connect the mounted components to each other.

According to a fifth aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps; and a conductive pad disposed at aperiphery of an area receiving the conductive bumps on the interposersubstrate so as to receive a connecting wire.

In the multileveled printed circuit board unit employing the interposer,the connecting wire can simply be employed to establish an electricconnection between the mounted components. In addition, since theconductive pads are allowed to receive the connecting wire at theperiphery of the area receiving the conductive bumps on the interposersubstrate, it is possible to easily fix the connecting wire to thetarget conductive pad without disassembling the multileveled printedcircuit board unit.

According to a sixth aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps; and a conductive pad disposed at aperiphery of an area receiving the conductive bumps on the interposersubstrate so as to receive a probe.

In the multileveled printed circuit board unit employing the interposer,it is possible to easily conduct an inspection for electric connectionbetween the mounted component and the printed wiring substrate by simplycontacting the tip ends of inspection probes with the target conductivepads. The inspection may serve to reveal a disconnection of the wiringpattern formed on the printed wiring substrate, a disconnection of thewiring pattern within the mounted component, and a disconnection at therespective conductive bumps. Moreover, since the conductive pads areallowed to receive the inspection probe at the periphery of the areareceiving the conductive bumps on the interposer substrate, it ispossible to easily contact the inspection probe with the targetconductive pad without disassembling the multileveled printed circuitboard unit.

According to a seventh aspect of the present invention, there isprovided an interposer for a multileveled printed circuit board unit inwhich conductive bumps are stacked between a printed wiring substrateand a mounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps; and a heat radiator attached to theinterposer substrate.

In the multileveled printed circuit board unit employing the interposer,when the electric circuit operates to generate heat in the interposersubstrate, heat radiation from the interposer substrate can be promotedthrough the heat radiator. The heat radiator may take the form of a fin,a thermal conductive pattern formed on the surface of the interposersubstrate, and the like.

According to an eighth aspect of the present invention, there isprovided an interposer for a multileveled printed circuit board unit inwhich conductive bumps are stacked between a printed wiring substrateand a mounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps; and a standoff member standing on theinterposer substrate so as to receive at least one of the printed wiringsubstrate and the mounted component at its tip end.

Employment of the interposer enables a method of mounting a component ona printed wiring substrate, comprising: preparing an interposerincluding a standoff member standing on an interposer substrate;preparing conductive bumps stacked between the printed wiring substrateand the component while allowing the interposer interposed betweenstacked conductive bumps; and ref lowing the conductive bumps while theinterposer and the component are urged against the printed wiringsubstrate. In this method, a pressure during a ref lowing processenables leveling the height of the resulting conducive bumps, regulatedby the height of the standoff member, on the identical level even if anirregularity can be found in the height of the conductive bumps on theidentical level before ref lowing. The respective conductive bumpsreliably achieve a bonding between the mounted component and interposersubstrate as well as between the interposer substrate and the printedwiring substrate.

According to a ninth aspect of the present invention, there is providedan interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps; and a guide member located on theinterposer substrate at a predetermined location for adjustment of arelative position between the printed wiring substrate and the mountedcomponent.

The guide member serves to prevent a displacement or slippage of themounted component relative to the printed wiring substrate even when theconductive bumps are caused to melt during a ref lowing process. Theconductive bumps can reliably be bonded to the corresponding electrodepads on the mounted component, the interposer substrate and the printedwiring substrate, respectively.

The aforementioned interposers can be applied to a multileveled printedcircuit board unit comprising: a printed wiring substrate; a componentto be mounted on the printed wiring substrate; and conductive bumpsstacked between the printed wiring substrate and the mounted component.It should be noted that the mounted component may include a ball gridarray (BGA) device, a pin grid array (PGA) device, a flip chip, a chipfor a multichip module (MCM), and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will become apparent from the following description of thepreferred embodiments in conjunction with the accompanying drawings,wherein:

FIGS. 1A to 1D are side views schematically illustrating the structureof a multileveled printed circuit board unit comprising solder bumpsstacked one another between a printed wiring substrate and a mountedcomponent, and a method of producing the same;

FIGS. 2A and 2B are side views illustrating the structure of an assemblycomprising a mounted component and an interposer substrate;

FIG. 3 is a side view illustrating a joined structure of interposersubstrates;

FIGS. 4A and 4B are side view illustrating the structure of amultileveled printed circuit board unit filled with a potting material;

FIGS. 5A and 5B are side Views illustrating the structure of an assemblycomprising a mounted component and an interposer substrate filled with apotting material;

FIG. 6 is a side view illustrating a joined structure of interposersubstrates filled with a potting material;

FIG. 7 is a plan view illustrating an interposer substrate according toa first embodiment of the present invention;

FIG. 8 is an enlarged partial sectional view taken along the line 8-8 inFIG. 7;

FIG. 9 is a plan view illustrating an interposer substrate according toa second embodiment of the present invention;

FIG. 10 is an enlarged partial sectional view taken along the line 10-10in FIG. 9;

FIG. 11 is a plan view illustrating a modification of the interposersubstrate according to the second embodiment of the present invention;

FIG. 12 is a side view illustrating an interposer substrate according toa third embodiment of the present invention;

FIG. 13 is an enlarged partial sectional view illustrating the structureof an interposer substrate according to a fourth embodiment of thepresent invention;

FIG. 14 is a sectional view illustrating the behavior of the interposersubstrate;

FIG. 15 is a side view schematically illustrating the structure of amultileveled printed circuit board unit comprising an interposersubstrate according to a fifth embodiment of the present invention, anda method of producing the same;

FIG. 16 is a side view schematically illustrating the structure of amultileveled printed circuit board unit comprising an interposersubstrate according to a sixth embodiment of the present invention, anda method of producing the same;

FIGS. 17A and 17B is plan and side views illustrating the structure of amultileveled printed circuit board unit comprising an interposersubstrate according to a seventh embodiment of the present invention;

FIGS. 18A and 18B are plan and side views illustrating a modifiedexample of a multileveled printed circuit board unit employing theinterposer substrate according to the seventh embodiment;

FIG. 19 is a plan view illustrating an interposer substrate according toan eighth embodiment of the present invention;

FIGS. 20A and 20B are plan and side views of the multileveled printedcircuit board unit for illustrating the function of the interposersubstrate according to the eighth embodiment;

FIG. 21 is a plan view illustrating an interposer substrate according toa ninth embodiment of the present invention;

FIGS. 22A and 22B are plan and side views of the multileveled printedcircuit board unit for illustrating the function of the interposersubstrate according to the ninth. embodiment;

FIGS. 23A and 23B are plan and side views of the multileveled printedcircuit board unit for illustrating the function of the interposersubstrate according to the ninth embodiment;

FIG. 24 is a side view illustrating an interposer substrate according totenth embodiment of the present invention;

FIG. 25 is a plan view illustrating a modified example of the interposersubstrate according to the tenth embodiment;

FIG. 26 is a side view schematically illustrating the structure of amultileveled printed circuit board unit comprising an interposersubstrate according to an eleventh embodiment of the present invention,and a method of producing the same;

FIG. 27 is a side view illustrating an example of an interposersubstrate according to the eleventh embodiment;

FIG. 28 is a side view illustrating another example of an interposersubstrate according to the eleventh embodiment;

FIG. 29 is a side view illustrating further example of an interposersubstrate according to the eleventh embodiment;

FIG. 30 is a side view illustrating still further example of aninterposer substrate according to the eleventh embodiment;

FIG. 31 is a side view illustrating still further example of aninterposer substrate according to the eleventh embodiment;

FIG. 32 is a side view schematically illustrating the structure of amultileveled printed circuit board unit comprising an interposersubstrate according to a twelfth embodiment of the present invention,and a method of producing the same;

FIG. 33 is a side view illustrating another example of an interposersubstrate according to the twelfth embodiment;

FIG. 34 is a side view illustrating further example of an interposersubstrate according to the twelfth embodiment;

FIG. 35 is a plan view illustrating still further example of aninterposer substrate according to the twelfth embodiment; and

FIG. 36 is a plan view illustrating still further example of aninterposer substrate according to the twelfth embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1D illustrates a multileveled printed circuit board unit. Theprinted circuit board unit 10 includes a printed wiring substrate 11 onwhich conductive or electrode pads and a conductive or wiring patternfor electrically connecting the electrode pads are printed. The printedwiring substrate 11 may be made of a resin material such as a glassepoxy resin, a polyimide resin, or the like.

A component 12 is mounted on the printed wiring substrate 11. Thecomponent 12 is fixed on the printed wiring substrate 11 withmultileveled or stacked solder bumps 13 disposed between the printedwiring substrate 11 and the component 12. The component 12 can berepresented by a ball grid array (BGA) device, a flip chip, and thelike. The component 12 may include a ceramic substrate 14, for example.

An interposer or relay substrate 15 is interposed between the upper andlower solder bumps 13 a, 13 b of the stacked solder bumps 13. A via, notshown, may be formed in the interposer substrate 15 so as toelectrically connect the upper and lower solder bumps 13 a, 13 b. Whenthe solder bumps 13 are stacked over three or more levels one another,the interposer substrate 15 can be interposed between the respectivepairs of upper and lower solder bumps 13.

As shown in FIG. 1A, when the component 12 is mounted on the printedwiring substrate 11, the upper and lower solder bumps 13 a, 13 b may beformed on the component 12 and the printed wiring substrate 11,respectively. After the interposer substrate 15 is interposed betweenthe upper and lower solder bumps 13 a, 13 b, a reflowing process of thesolder bumps 13 a, 13 b is conducted. As shown in FIG. 1B, the upper andlower bumps 13 a, 13 b may be attached to the component 12 and theinterposer substrate 15, respectively, when the upper and lower solderbumps 13 a, 13 b are stacked between the component 12 and the printedwiring substrate 11. Furthermore, as shown in FIG. 1C, the upper andlower solder bumps 13 a, 13 b may be formed on opposite surfaces of theinterposer substrate 15 when the stacked solder bumps 13 are disposedbetween the component 12 and the printed wiring substrate 11. When a reflowing process is conducted, an assembly of the component 16 and theinterposer substrate 15 may previously be prepared, as shown in FIGS. 2Aand 2B. Alternatively, a joined structure 17 of the interposersubstrates 15 may be employed, as shown in FIG. 3.

A potting material 18 may be supplied to enclose the upper and/or lowersolder bumps 13 a, 13 b. As shown in FIG. 4A, the potting material 18may simply be introduced into a space between the printed wiringsubstrate 11 and the lowest interposer substrate 15. Alternatively, thepotting material 18 may fill up an overall space between the printedwiring substrate 11 and the component 12 for completely enclosing theinterposer substrate 15 as shown in FIG. 4B. An assembly of thecomponent 19 and the interposer substrate 15, filled with the pottingmaterial 18, may previously be prepared, as shown in FIGS. 5A and 5B.Otherwise, a joined structure 20 of the interposer substrates 15, filledwith the potting material 18, may be employed, as shown in FIG. 6.

FIG. 7 illustrates an interposer or relay substrate 22 according to afirst embodiment of the present invention. A plurality of conductiveelectrode pads 23 are arranged on the upper surface of the interposersubstrate 22 in a grid array so as to correspond to respectiveconductive electrode pads on the component 12 to be mounted. As shown inFIG. 8, a plurality of conductive electrode pads 24 are also arranged onthe lower surface of the interposer substrate 22 so as to correspond tothe respective electrode pads 23 on the upper surface. The electrodepads 24 on the lower surface also correspond to respective conductiveelectrode pads on the printed wiring substrate 11. Vias 25 serve toestablish electric connections between the electrode pads 23 on theupper surface and the corresponding electrode pads 24 on the lowersurface.

The interposer substrate 22 is made of a porous material sheet or filmdefining tiny pores 26. The respective pores 26 are designed topenetrate through the interposer substrate 22 in the direction of itsthickness. The electrode pads 23 on the upper surface suffer from arelatively smaller displacement or shift P1 along the upper surface ofthe interposer substrate 22 when an expansion is induced in thecomponent 12. On the other hand, the electrode pads 24 on the lowersurface suffer from a relatively larger displacement or shift P2 alongthe lower surface of the interposer substrate 22 when an expansion isinduced in the printed wiring substrate 11. A shearing stress is thusinduced between the electrode pads 23, 24 in the interposer substrate22. The pores 26 are allowed to deform absorbing the shearing stress inthe porous material sheet. Accordingly, less shearing stress is inducedin the solder bumps 13 a, 13 b bonded on the respective electrode pads23, 24. Moreover, since the tiny pores 26 can selectively be employed toestablish the vias 25, it is not necessary to bore the interposersubstrate 22 solely for the vias 25. Production process of theinterposer substrate 22 can be facilitated. Here, the porous materialsheet is preferably made of a high elastic material. The porous materialsheet can be formed by utilizing a foamed agent introduced in a resinmaterial in molding.

FIGS. 9 and 10 illustrate an interposer or relay substrate 28 accordingto a second embodiment of the present invention. A plurality ofconductive electrode pads 29, 30 are likewise arranged on the upper andlower surfaces of the interposer substrate 28, respectively, in the samemanner as the aforementioned first embodiment. Vias 31 serve toestablish electric connections between the electrode pads 29 on theupper surface and the corresponding electrode pads 30 on the lowersurface.

The interposer substrate 28 is designed to define slits 32 penetratingthrough the interposer substrate 28 in the direction of its thickness.The respective slits 32 are located between the adjacent ones of theelectrode pads 29, 30 arranged on the identical level. When theelectrode pads 29 suffer from a relatively smaller displacement or shiftP1 while the electrode pads 30 suffer from a relatively largerdisplacement or shift P2 in the aforementioned manner, the respectiveslits 32 are allowed to deform so as to absorb a shearing stress inducedbetween the electrode pads 29, 30 in the interposer substrate 28.Accordingly, less shearing stress is induced in the solder bumps 13 a,13 b bonded on the respective electrode pads 29, 30. In particular, thesize of the slits 32 at the central area of the interposer substrate 28is preferably set smaller than that of the slits 32 located at the arearemoter from the central area, as shown in FIG. 11, since the planardisplacement or shift. P1, P2 gets larger at a location remoter from thecenter of the interposer substrate 28 upon a thermal expansion of theprinted wiring substrate 11 and the component 12.

FIG. 12 illustrates an interposer or relay substrate 34 according to athird embodiment of the present invention. In this embodiment, theinterposer substrate 34 is shaped to have undulation in thecross-section. The interposer substrate 34 is allowed to absorb ashearing stress caused by the planar displacement or shift P1, P2without utilizing the aforementioned pores 26 and the slits 32.Accordingly, less shearing stress is induced in the solder bumps 13 a,13 b bonded on the upper and lower surfaces of the interposer substrate34.

FIG. 13 illustrates an interposer or relay substrate 36 according to afourth embodiment of the present invention. In this embodiment, theinterposer substrate 36 includes a multilayered films comprising a firstfilm 37 and a second film 38 superposed on the first film 37. The firstfilm 37 is made of an inorganic material such as a ceramic material inthe same manner as the ceramic substrate 14 of the component 12. Thesecond film 38 is made of an organic material such as a glass epoxy orpolyimide resin in the same manner as the printed wiring substrate 11.An adhesive layer 39 made of an adhesive, for example, is interposedbetween the first and second films 37, 38 so as to adhere the first andsecond films 37, 38 to each other.

Assume that the ceramic substrate 14 and the printed wiring substrate 11suffer from a thermal expansion, respectively. As shown in FIG. 14, thefirst film 37 is supposed to expand in unison with the expansion of theceramic substrate 14 of the component 12 while the second film 38 issupposed to expand in unison with the expansion of the printed wiringsubstrate 11 in this case. The adhesive layer 39 serves to allow asliding movement between the first and second films 37, 38. A naturalthermal expansion can be accepted in the first and second films 37, 38,respectively, irrespective of the difference in the thermal expansioncoefficients. No shearing stress is induced in the solder bumps 13 a, 13b. The stacked solder bumps 13 a, 13 b with the interposer substrate 36interposed therebetween can absorb a remarkable shearing stress. Thelevels of the stacked solder bumps 13 can accordingly be reduced. Inthis embodiment, vias 40 are preferably made of an elastic andelectrically conductive material, since the aforementioned slidingmovement cannot be achieved between the first and second films 37, 38without deformation of the vias 40.

FIG. 15 illustrates a multileveled printed circuit board unit 42employing an interposer or relay substrate according to a fifthembodiment of the present invention. The printed circuit board unit 42includes solder bumps 43 a, 43 b, 43 c of different sizes or diametersstacked one another between the component 12 and the printed wiringsubstrate 11. The interposer substrate 15 is interposed between therespective pairs of upper and lower solder bumps 43 a, 43 b, 43 c. Thesolder bumps 43 a, 43 b, 43 c on the identical level may have the samediameter, respectively. In general, the larger the size or diameter of asolder bump gets, the larger the strength of the solder bump can beobtained. Even when different strengths are required in the separatelevels of the stacked solder bumps 43, it is possible to minimize thesize or diameter of the solder bumps 43 a, 43 b, 43 c. The overallheight of the stacked solder bumps 43 can thus be reduced, keeping arequired strength. Like reference numerals are attached to thestructures accomplishing the function and effect identical to that ofthe structure included in the aforementioned embodiments. Detaileddescriptions have been omitted.

FIG. 16 illustrates a multileveled printed circuit board unit 45employing an interposer or relay substrate according to a sixthembodiment of the present invention. In this embodiment, solder bumps 46a, 46 b, 46 c are made of different materials, so that diffusion bondingof various strengths can be obtained between the solder bumps 46 a, 46b, 46 c and the interposer substrates 15 as well as the othersubstrates, respectively. Even when the solder bumps 46 a, 46 b, 46 care designed to have the same size or diameter, it is possible toseparately set the strength of the solder bumps 46 a, 46 b, 46 c of therespective levels. In general, a material of the solder bump is selectedfrom Pb—Sn materials in a mounted component such as a BGA device. On theother hand, a leadless cream solder is often printed on a printed wiringsubstrate. If such a BGA device is directly mounted on the printedwiring substrate, the Pb—Sn solder may be mixed with the leadlesssolder. Such mixture of the Pb—Sn material and the leadless soldersometimes serves to reduce a bonding strength. If the interposersubstrate 15 is interposed between the component 12 and the printedwiring substrate 11, it is possible to prevent the Pb—Sn solder bumps 46a on the component 12 from being mixed with the leadless solder bumps 46b, 46 c on the interposer substrate 15 and the printed wiring substrate11. Moreover, employment of the interposer substrate 15 allows thetreatment of the cream solder having a relatively lower melting point tobe conducted separately from the treatment of the solder bumps 46 ahaving a relatively higher melting point. Specifically, after thecomponent 12 has been mounted on the interposer substrate 15 in theatmosphere of a higher temperature, a reflowing process can be effectedto mount the interposer substrate 15 on the printed wiring board 11 at alower temperature.

FIGS. 17A and 17B illustrate a multileveled printed circuit board unit48 employing an interposer or relay substrate 50 according to a seventhembodiment of the present invention. A conductive wiring pattern isformed on the interposer substrate 50 so as to establish an electricconnection at least between conductive or solder bumps 49 a, 49 b on theidentical level in the printed circuit board unit 48. As is apparentfrom FIG. 17A, a plurality of conductive electrode pads 51 are arrangedon the upper surface of the interposer substrate 50 in a grid array. Theconductive wiring pattern 52 is formed on the upper surface of theinterposer substrate 50 so as to connect the electrode pad 51 acorresponding to the solder bump 49 a and the electrode pad 51 bcorresponding to the solder bump 49 b. In this printed circuit boardunit 48, the conductive wiring pattern 52 on the interposer substrate 50may serve to establish an alternative electric path for a disconnectedwiring pattern on the printed wiring substrate 11 and/or the component12. Also, the conductive wiring pattern 52 may establish a modifiedelectric path in place of a wiring pattern initially formed on theprinted wiring substrate 11 and/or the component 12. Like referencenumerals are attached to the structures accomplishing the function andeffect identical to that of the structure included in the aforementionedembodiments. Detailed descriptions have been omitted.

As, shown in FIGS. 18A and 18B, two or more components 12 may be mountedon the interposer substrate 50. In such a printed circuit board unit 48,the conductive wiring pattern 52 on the interposer substrate 50 mayserve to establish an alternative electric path for a disconnectedwiring pattern on the printed wiring substrate 11 so as to electricallyconnect the components 12 to each other. Otherwise, the conductivewiring pattern 52 may establish a modified electric path for a wiringpattern initially formed on the printed wiring substrate 11 so as toconnect the components 12 to each other.

FIG. 19 illustrates an interposer or relay substrate 54 according to aneighth embodiment of the present invention. A plurality of conductiveelectrode pads 55 are arranged on the upper surface of the interposersubstrate 54 in a grid array in correspondence with electrode pads onthe component 12. Likewise, conductive pads 56 are arranged on the uppersurface of the interposer substrate 54 at a periphery of an areareceiving the conductive electrode pads 55 so as to receive a connectingwire. A conductive wiring pattern 57 is designed to establish anelectric connection between the specific electrode pads 55 and theconductive pads 56 in a one-to-one correspondence.

As shown in FIGS. 20A and 20B, the connecting wire 58 can be employed toestablish an electric connection between the components 12 mounted onthe printed wiring substrate 11. For example, the interposer substrate48 shown in FIGS. 18A and 18B may be employed to likewise connect thecomponents 12 to each other on the printed wiring substrate 11. However,if the components 12 are spaced apart from each other on the printedwiring substrate 11, the interposer substrate 48 should be made largerenough. On the other hand, the connecting wire 58 alone is simplyutilized to connect the components 12 to each other withoutunnecessarily enlarging the size of the interposer substrate 48 in thisembodiment. Moreover, since the conductive pads 56 are allowed toreceive the connecting wire 58 at the periphery of the area receivingthe solder bumps 13 a on the interposer substrate 54, it is possible toeasily fix the connecting wire 58 to the target conductive pad 56without disassembling the multileveled printed circuit board unit.

FIG. 21 illustrates an interposer or relay substrate 60 according to aninth embodiment of the present invention. A plurality of conductiveelectrode pads 61 are arranged on the upper surface of the interposersubstrate 60 in a grid array in correspondence with respective electrodepads on the component 12. Likewise, conductive pads 62 are arranged onthe upper surface of the interposer substrate 60 at a periphery of anarea receiving the conductive electrode pads 61 so as to receive aprobe. A conductive wiring pattern 63 is designed to establish anelectric connection between the specific electrode pads 61 and theconductive pads 62 in a one-to-one correspondence.

As shown in FIGS. 22A and 22B, it is possible to easily conduct aninspection for electric connection between the component 12 and theprinted wiring substrate 11 by simply contacting the tip ends ofinspection probes 65 with the target conductive pads 62. The inspectionmay serve to reveal a disconnection of the wiring pattern formed on theprinted wiring substrate 11, a disconnection of the wiring patternwithin the component 12, and a disconnection at the respective solderbumps 13 a, 13 b. Moreover, since the conductive pads 62 are allowed toreceive the inspection probe 65 at the periphery of the area receivingthe solder bumps 13 a on the interposer substrate 60, it is possible toeasily contact the inspection probe 65 with the target conductive pad 62without disassembling the multileveled printed circuit board unit.

In addition, the conductive pads 62 may be located on the interposersubstrates 60 a, 60 b of various levels, as shown in FIGS. 23A and 23B.In this case, an upper interposer substrate 60 a is preferably madesmaller than a lower interposer substrate 60 b. With this arrangement,the inspection probes 65, 66 are always allowed to approach theconductive pads 62 in a vertical direction.

FIG. 24 illustrates an interposer or relay substrate 67 according to atenth embodiment of the present invention. A heat radiator 68 isattached to the interposer substrate 67. The heat radiator 68 comprisescooling fins 69 located at the periphery of the area receiving thesolder bumps 13 a, 13 b. When the electric circuit operates to generateheat in the interposer substrate 67, heat radiation from the interposersubstrate 67 can be promoted through the cooling fins 69. The coolingfins 69 are preferably made of a high thermal conductivity material suchas a metal.

As shown in FIG. 25, the heat radiator 68 may comprise a thermalconductive pattern 70 formed on the surface of the interposer substrate67. The thermal conductive pattern 70 may be shaped in a grid so as tobe located off the conductive electrode pads 71. The thermal conductivepattern 70 is preferably made of a high thermal conductivity materialsuch as a metal. Additionally, the heat radiator 68 may comprise notonly the thermal conductive pattern 70 but also the aforementionedcooling fins 69. In this case, the cooling fins 69 are preferablyconnected to the thermal conductive pattern 70.

FIG. 26 illustrates a multileveled printed circuit board unit 73employing an interposer or relay substrate according to an eleventhembodiment of the present invention. When the printed circuit board unit73 is to be fabricated, the stacked solder bumps 13 are first prepared.The stacked solder bumps 13 are interposed between the printed wiringsubstrate 11 and the component 12. In this case, the upper solder bumps13 a among the stacked solder bumps 13 may be formed on the component12, while the lower solder bumps 13 b may be formed on the interposersubstrate 74. The interposer substrate 74 is also previously prepared.Stand off members 75 have been fixed on the interposer substrate 74. Thestandoff members 75 are designed to stand on the upper and lowersurfaces of the interposer substrate 74. The thus prepared interposersubstrate 74 and the component 12 are sequentially placed on the printedwiring substrate 11. During a reflowing process, the component 12 andthe interposer substrate 74 are urged against the printed wiringsubstrate 11 by their own weight and an additional urging force 77. Thesolder bumps 13 a, 13 b are allowed to melt under a pressurizedcondition. The printed wiring substrate 11 is thereafter cooled down.The standoff members 75 serve to keep a predetermined space between theprinted wiring substrate 11 and the component 12, so that the solderbumps 13 a, 13 b can be prevented from excessively squashing in apressurized condition. A pressure during a reflowing process enablesleveling the height of the final solder bumps 13 a, 13 b, regulated bythe height of the standoff members 75, on the identical level even if anirregularity can be found in the height of the solder bumps 13 a, 13 bon the identical level before reflowing. The respective solder bumps 13a, 13 b reliably achieve a bonding between the component 12 andinterposer substrate 74 as well as between the interposer substrate 74and the printed wiring substrate 11.

As shown in FIG. 27, the standoff member 75 may be a solder bump of ahigher melting point located at corners of the area receiving the solderbumps 13 b. The solder bump of a higher melting point is refrained frommelting during the reflowing process of the solder bumps 13 a, 13 b, sothat the standoff members 75 is allowed to keep its shape and heightduring the reflowing. In place of the solder bump, the standoff member75 may be a pin, as shown in FIG. 28. In addition, the standoff members75 are not necessarily located outside the area receiving the solderbumps 13 b. As shown in FIG. 29, the standoff member 75 can be embeddedin a via connecting the upper and lower solder bumps 13 a, 13 b to eachother. Furthermore, the standoff member 75 may be formed as a protrusionintegral to the conductive electrode pads, as shown in FIGS. 30 and 31.

FIG. 32 illustrates a multileveled printed circuit board unit 80employing an interposer or relay substrate according to a twelfthembodiment of the present invention. The printed circuit board unit 80includes guide members 81 located on the interposer substrate 82 at apredetermined position for adjustment of a relative position between theprinted wiring substrate 11 and the component 12. The guide member 81 isreceived in a guide bore 83 defined in the component 12 and a guide bore84 defined in the printed wiring substrate 11. The guide members 81serve to prevent a displacement or slippage of the component 12 relativeto the printed wiring substrate 11 even when the solder bumps 13 a, 13 bare caused to melt during a reflowing process. The solder bumps 13 a canreliably be bonded to the corresponding electrode pads on the interposersubstrate 82, respectively, while the solder bumps 13 b can reliably bebonded to the corresponding electrode pads on the printed wiringsubstrate 11.

As shown in FIG. 33, the guide member 81 may be allowed to protrude fromone of the upper and lower surfaces of the interposer substrate 82.Alternatively, the guide member 81 may protrude from both the upper andlower surfaces of the interposer substrate 82, as shown in FIG. 34. Whena plurality of interposer substrates 82 are interposed between theprinted wiring substrate 11 and the component 12, the interposersubstrate 82 solely defining the guide bores 85 can be employed, asshown in FIG. 35. Otherwise, the guide members 81 and the guide bores 85may be disposed in every interposer substrate 82, as shown in FIG. 36.

1. An interposer for a multileveled printed circuit board unit in whichconductive bumps are stacked between a printed wiring substrate and amounted component, comprising: an interposer substrate interposedbetween stacked conductive bumps, the interposer substrate having upperand lower surfaces; conductive pads formed on the upper surface of theinterposer substrate, each of the conductive pads being designed toreceive a corresponding one of the stacked conductive bumps at a firstlevel; auxiliary conductive pads formed on the lower surface of theinterposer substrate, each of the auxiliary conductive pads beingconnected to a corresponding one of the conductive pads through a viaformed in the interposer substrate, each of the auxiliary conductivepads being designed to receive a corresponding one of the stackedconductive bumps at a second level adjacent to the first level; and aconductive wiring pattern formed on at least one of the upper and lowersurfaces of the interposer substrate so as to establish electricconnection between at least two of at least corresponding ones of theconductive pads or auxiliary conductive pads.
 2. A multileveled printedcircuit board unit comprising: a printed wiring substrate; a mountedcomponent received above the printed wiring substrate; conductive bumpsstacked between the printed wiring substrate and the mounted component;an interposer substrate interposed between the conductive bumps at afirst level and the conductive bumps at a second level adjacent thefirst level, the interposer substrate having upper and lower surfaces;conductive pads formed on the upper surface of the interposer substrate,each of the conductive pads being designed to receive a correspondingone of the stacked conductive bumps at a first level; auxiliaryconductive pads formed on the lower surface of the interposer substrate,each of the auxiliary conductive pads being connected to a correspondingone of the conductive pads through a via formed in the interposersubstrate, each of the auxiliary conductive pads being designed toreceive a corresponding one of the stacked conductive bumps at a secondlevel adjacent to the first level; and a conductive wiring patternformed on at least one of the upper and lower surfaces of the interposersubstrate so as to establish electric connection between at least two ofat least corresponding ones of the conductive pads or auxiliaryconductive pads.